Assembly fixture for constructing superheater and/or reheater modules

ABSTRACT

A fixture for shop assembly of superheater and/or reheater modules including a structural frame having accurately machined surfaces to enable exact positioning of a segment of a superheater or reheater header in a particular orientation with respect to a lifting and shipping frame mounted on a fixed reference base. The module may then be completed by placing individual superheater or reheater tube panels in the frame and joining them to the header.

United States Patent Sullivan et al.

[ 51 Feb. 29, 1972 [54] ASSEMBLY FIXTURE FOR CONSTRUCTING SUPERHEATERAND/OR REHEATER MODULES [72] Inventors: Robert P. Sullivan, Chattanooga;John N.

McClain, Signal Mountain, both of Tenn.

[73] Assignee: Combustion Engineering, Inc., Windsor,

Conn.

[22] Filed: Apr. 28, 1970 21] Appl. No.: 32,573

[52] U.S. Cl. ..29/202 R, 228/49, 269/132 [5 l] Int. Cl ..B23p 15/26[58] Field of Search ..29/202 R, 200 P, 200 J, 33 G,

29/l59.4; l65/l72, 173; 228/6, 47, 49; 269/55, 60, 82, 131, I32, 287,299, 95

[56) References Cited UNITED STATES PATENTS 2,775,810 l/l957 Galehouse..29/l57.4

Primary Examiner-Theron E. Condon Assistant Examiner-Robert L. SpruillAttorney-Carlton F. Bryant, Eldon H. Luther, Robert L. Olson, John F.Carney, Richard H. Berneike, Edward L. Kochey, Jr. and Lawrence P.Kessler [57] ABSTRACT A fixture for shop assembly of superheater and/orreheater modules including a structural frame having accurately machinedsurfaces to enable exact positioning of a segment of a superheater orreheater header in a particular orientation with respect to a liftingand shipping frame mounted on a fixed reference base. The module maythen be completed by placing individual superheater or reheater tubepanels in the frame and joining them to the header.

9 Claims, 9 Drawing Figures Patented Feb. 29, 1972 5 Sheets-Sheet lINVENTOR. R.P. SULLIVAN BY J-N- M CLAIN atented Feb 9 197 I 44 97 5Sheets-Sheet 3 v F/6 G INVENTOR, 2.12 SULLIVAN v. M CLA/N BY Z Q 2Patented Feb. 29, 1972 5 Sheets-Sheet 4.

INVENTOR, R SUL L/VAN BYW/M Pt td Fb.29,1972

5 Sheets-Sheet 5 INVENTOR. 2.1 SULLIVAN J/v. MC CLA/N OZZJW ASSEMBLYFIXTURE FOR CONSTRUCTING SUPERI-IEATER AND/OR REHEATER MODULESBACKGROUND OF THE INVENTION The construction of boiler units for steamgeneration in utility power plants and large industrial facilities isaccomplished directly at the location selected for the plant. This isdue to the size and lack of standardized construction of thesefacilities. Field erection is expensive in that construction anderection equipment must be brought to the building site and erectionefficiency is dependent upon a transient labor market of inconsistentquality.

The advantages of shop assembly, as opposed to field erection, have longbeen realized in the manufacture of industrial boilers of somewhatsmaller size. Standard designs with Standard designs with maximum use ofstandardized use of standardized fabrication procedures considerablyreduces the cost of these units over comparably sized field erectedunits. Additionally, labor control is more readily accomplished so as toinsure more reliable and efficient construction of the boiler equipment.

While overall economy of construction of utility plant and largeindustrial boilers is dependent upon many factors, in general there isan attempt to optimize this economy by utilizing shop assemblytechniques where shipping considerations permit. Boiler components, andthe procedures for the fabrication thereof, whenever possible are beingstandardized and moved into the shop so as to maintain more accuratecontrol over their manufacture as well as reducing their cost.

When high final steam temperatures for the above-noted facilities arerequired, panel-type superheaters and reheaters are necessary to providethe required heat transfer surfaces. In the past, superheater andreheater construction for these boiler systems has necessarily beenaccomplished in the field. 'l'hesc superheater and reheater arrangementswere constructcd by hanging headers and then raising and weldingindividual tube panels thereto. This construction technique was not onlyexpensive and time consuming but required a large number of accuratefield welds by skilled welders which are not always available.

SUMMARY OF THE INVENTION It is the purpose of this invention to providea novel apparatus which permits shop assembly of superheaters and/orreheaters for utility plants and large industrial boilers. A shopassembly fixture is provided which has specifically machined surfaces toenable accurate positioning of a segment of a superheater or reheaterheader in a vertical orientation with respect to a lifting and shippingframe. Individual tube panels are placed in the frame and joined to theheader until a complete module is built up. The module may then beconveniently shipped to the erection site in its frame where it may bepositioned and joined to similar modules to form the unitary superheateror reheater structure.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a side elevation of theassembly fixture for constructing superheater and/or reheater modulesaccording to this invention.

FIG. 2 is a plan view of the structural frame tower and module supportof FIG. 1.

FIG. 3 is a side elevational view of the structure of FIG. 2.

FIG. 4 is a plan view of the mounting plate of FIG. 1.

FIG. 5 is a side elevational view of the mounting plate of FIG. 4.

FIG. 6 is a rear elevational view of the mounting plate of FIG. 4.

FIG. 7 is a side elevational view of the V-slide base of FIG.

FIG. 8 is a plan view of the V-slide assembly of FIG. 1.

FIG. 9 is a side elevational view of the V-slide assembly of FIG. 8.

Referring to the drawings, FIG. 1 shows an overall view of the assemblyfixture for constructing superheater and/or reheater modules accordingto this invention. The superheater or reheater modules 10 are elementsof a superheater or reheater structure for a large steam generator. Themodules 10 are built up on an assembly fixture 12 in a lifting andshipping frame 14. On completion of each module 10 in the frame 14, apackage is formed which facilitates handling and shipping of the modulesto the erection site for final assembly into a unitary superheater orreheater structure. a

The assembly fixture 12 comprises a structural frame tower 18 mounted onthe fixed reference base 16 (FIG. 2). In relation to the tower 18 thereis positioned a bed plate 20 and bed rails 22 on the fixed referencebase 16 for support of the module 10 during assembly. The structuralframe tower I8 has mounted thereon longitudinally oriented machinedsurfaces 24 accurately positioned with respect to the reference base 16.The tower 18 may have additional machined surfaces 24 mounted on theside opposite from V-slide assembly 60 relative to the V-slide base 42.The baseplate 62 additionally has bosses 76 through which a lockinghandle 78 extends. This locking handle 78 passes through an endconnection 80 of a header retention cable 82 for the purpose to beexplained hereinbelow.

A header locating plate 84 is positioned on the standard 64 and hastracks 86 which are engaged with guide bearings 68 of the V-slideassembly 60 so as to permit relative movement therebetween. The headerlocating plate 84 has a V-notch 88 in the outwardly extending end (FIG.8 shows two half views of the header locating plate 84, the first headerlocating plate 84 with notch 88 for the purpose of supporting largeheaders and the second header locating plate 84' with notch 8 8 forsmaller headers) and a ram reaction plate 90 mounted centrally thereon.As seen in FIG. 7, an hydraulic ram 92 actuated by an hydraulic actuator94 is positioned between the ram reaction plate 90 and the baseplate 62of the V-slide assembly 60 to control the position of the headerlocating plate 84. Blocks 96 (FIG. 8) are inserted between the headerlocating plate 84 and the baseplate 62 to maintain their relativepositions.

The assembly fixture 12 is utilized in assembly of superheater orreheater elements or modules 10 in the following manner. A segment ofthe superheater or reheater header 98 having tube nipples 100 extendingtherefrom is positioned on the header locating plates 84 of the V-slideassemblies 60, the V-slide assemblies in turn being positioned on theV-slide base 42 so as to support the ends of the header 98 and clampedin the supporting position by clamps 74. The header 98 is retainedagainst the header locating plates 84 by the header retention cables 82which are locked by the locking handles 78. The end of the header 98 issupported by the header support means 56 and longitudinal positioningjack 54.

After the hydraulic jack 92 is actuated to move the header locatingplate 84 to accurately position the header 98 with respect to the base44 of the V-slide base 42, the V-slide base 42 is lifted by means (notshown) engaging the lifting holes 50 in the upper extension 48 liftingand positioning the guide rollers 46 into the machined surfaces 24 inorder to accomplish simultaneous construction of several modules at onetime.

A mounting plate assembly 26 is particularly supported by the structuralframe tower 18 so as to maintain an accurate relationship with thereference base 16. As best seen in FIGS. 4-6, the mounting plateassembly 26 comprises a mounting plate 28 which has accurately machinedsurfaces 30 positioned thereon so as to mate with the machined surfaces24 to provide the desired accurate support therebetween. At the topportion of the plate 28 are mounted rollers 32 which serve to supportthe mounting plate assembly 26 and permit transverse adjustment thereofalong the machined surfaces 24'; Additionally, the plate 28 hashorizontal guides 34 which assist in the support and guiding of themounting plate assembly 26. The horizontal guides 34 have clamp means 36so as to secure the position of the mounting plate assembly 26 withreference to the structural frame tower 18 and the shipping frame 14when proper transverse positioning is accomplished. Extending from theplate 28 are V-slide base supports 38 which have particularly shapednotches 40 in the upper portions thereof for the purpose of accuratelysupporting the V-slide base 42.

The V-slide base 42 (best shown in FIG. 7) which serves to support theheader segment of module is comprised of a structural base 44 upon whichare mounted guide rollers 46 which engage the notches 40 of the V-slidebase supports 38 of the mounting plate assembly 26. The base 44 has anupper extension 48 which in turn has a series of holes 50 to permitlifting and positioning of the V-slide base 42. Additionally, thestructural base 44 has a lower extension 52 which supports alongitudinal positioning jack 54 and a header support means 56.

The structural base 44 has an integral slide track 58 upon which V-slideassemblies 60 may be positioned. The V-slide assembly 60, as best seenin FIGS. 8 and 9, is comprised of a baseplate 62 having a standard 64extending outwardly therefrom supported by web 66. The standard 64 hasguide bearings 68 mounted thereon. The baseplate 62 of the V-slideassembly 60 has guides 70 formed by blocks 72 affixed to the baseplate62. These guides 70 ride on the slide track 58 so as to be adjustablypositionable thereon. Clamp means 74 serve to secure the position of thenotches 40 of the mounting plate assembly 26 to accomplish the correctrelative positioning therebetween. The mounting plate 26 is accuratelypositioned on the machined surfaces 24 of the structural frame tower 18and clamped in position so that the header 98 is mounted in a verticalorientation and a fixed position relative to the structural frame tower18. The longitudinal positioning jack 56 may then be utilized toposition the header 98 with respect to its height above the fixedreference base 16. With the header so positioned, a lifting and shippingframe 14 is particularly positioned on the bed rails 22 so as to permittube panels 102 for the superheater or reheater module 10 to beaccurately positioned relative to the header 98 to build up the module10.

After the lifting and shipping frame 14 is positioned on the bed rails22, a first tube panel 102 is positioned in the frame l4 and welded tothe corresponding nipple 100 on the header 98. The welding isaccomplished by clamping the tube panel 102 to the respective tubenipples, tack welding the tubes and tube nipples, removing the clampsand completing the welding. After the welding of the first tube panel iscompleted, the next tube panel 102 is positioned in the frame 14 and theprocedure is repeated until a complete module 10 is built up. There maybe included with the tube panels 102 sealing means (not shown) servingto form the sealing wall of the boiler casing which are integrallywelded together as the module is built up. When the module is complete,the shipping frame 14 may be completed and the entire unit positionedfor shipping by the manipulation of the lifting and shipping frame 14.

In the assembly of certain superheater or reheater arrangements, headersegments are positioned on each end of the tube panels. This typeassembly is easily accomplished by providing a second mounting plate,V-slide base, and V-slide assembly supporting a second header segment.The second header segment is accurately positioned on the machinedsurfaces 24 by the mounting plate and relates structure to beparticularly located relative to the reference base 16 and the firstheader segment. The tube panels can then be readily joined to eachheader segment to form the desired superheater or reheater moduleconfiguration.

In view of the above, it can be seen that there is provided a novelmeans for shop assembling superheater and/or reheater modules. Byproviding a structural frame tower with accurately machined surfaces, itis possible to position a segment of a superheater or reheater header ina particular vertical orientation with respect to a lifting and shippingframe. With the header so positioned, tube anels can accurately bejoined to the header so that the modu e can readily be but t up in ashop environment.

While this preferred embodiment of the invention has been shown anddescribed, it will be understood that it is merely illustrative and thatchanges may be made without departing from the scope of the invention asclaimed.

We claim:

1. An apparatus for shop assembly of superheater or reheater modulescomprising:

a fixed reference base, a first support means mounted on said base, anupstanding structural frame tower mounted on said base, accuratelymachined surfaces particularly positioned on said structural frametower, a second support means for supporting in a vertical orientation asegment of a header to which tubes supported by said first support meansare to be joined to form said super-heater or reheater module, and meansfor accurately positioning said second supporting means on said machinedsurfaces of said structural frame tower so as to maintain a particularrelationship to said first support means.

2. The apparatus of claim I wherein said accurately machined surfacesinclude plural transverse elements fixed to said structural frame towerat spaced vertical intervals.

3. The apparatus of claim 2 wherein the means for positioning saidsecond support means includes at least one mounting plate, said at leastone mounting plate supported by and transversely movable with respect tosaid machined surfaces of said structural frame tower, said mountingplate further having complementary accurately machined surfaces matingwith said machined surfaces of said structural frame tower.

4. The apparatus of claim 3 wherein the means for positioning saidsupport means includes plural mounting plates, relatively movable withrespect to each other for accurate relative positioning thereof.

5. The apparatus of claim 3 wherein said second support means furtherincludes a header support base mounted on said at least one mountingplate.

6. The apparatus of claim 5 wherein said header support base includes alongitudinal trackway and a plurality of V- slide assemblies mounted onsaid trackway for selective relative movement with respect thereto.

7. The apparatus of claim 6 wherein said V-slide assemblies include abaseplate slidable along said longitudinal trackway, a standardextending outwardly from said baseplate, said standard having guidebearings thereon, a plate slidably mounted in said guide bearings havinga V-shaped notch in one end opposite said bottom plate for adjustablesupport engagement with said header, and a retention means for retainingsaid header against said V-shaped notch.

8. The apparatus of claim 7 wherein said retention means is anadjustable cable means entrained about said baseplate and fixed at itsends to said base 9. The apparatus of claim 7 wherein said headersupport base further includes a first jack means for moving said plateof said V-slide assemblies in said guide bearings, and a second jackmeans for positioning said header longitudinally with respect to saidheader support base.

at STATES PATENT OFFICE- lllQTE 0F CORRECTION latent No. 3, H97 Dat dFebruary 29 1972 po-woao (5/69) U lnventofls) Robert P. Sullivan andJohn N. McClain It is certified that error appears in the above'identified patent and that said Letters Patent are hereby corrected asshown below:

Column 1 line 16 of the patent delete "Standard designs with" Column 1,line lT, of the patent delete "standardized use of" Column 3, line 63,of the patent change "relates" to -related--. Column 4, line 59 of thepatent change "baseplate" to --header--.

Column l line 60, of the patent change "base" to ---baseplate.

Signed and sealed this 18th day of December 1973.

[SEAL] Attest:

EDWARD M.FLETCHER,JR. RENE D. T'EGTMEYER Attesting' Officer v ActingCommissioner of Patents

1. An apparatus for shop assembly of superheater or reheater modulescomprising: a fixed reference base, a first support means mounted onsaid base, an upstanding structural frame tower mounted on said base,accurately machined surfaces particularly positioned on said structuralframe tower, a second support means for supporting in a verticalorientation a segment of a header to which tubes supported by said firstsupport means are to be joined to form said super-heater or reheatermodule, and means for accurately positioning said second supportingmeans on said machined surfaces of said structural frame tower so as tomaintain a particular relationship to said first support means.
 2. Theapparatus of claim 1 wherein said accurately machined surfaces includeplural transverse elements fixed to said structural frame tower atspaced vertical intervals.
 3. The apparatus of claim 2 wherein the meansfor positioning said second support means includes at least one mountingplate, said at least one mounting plate supported by and transverselymovable with respect to said machined surfaces of said structural frametower, said mounting plate further having complementary accuratelymachined surfaces mating with said machined surfaces of said structuralframe tower.
 4. The apparatus of claim 3 wherein the means forpositioning said support means includes plural mounting plates,relatively movable with respect to each other for accurate relativepositioning thereof.
 5. The apparatus of claim 3 wherein said secondsupport means further includes a header support base mounted on said atleast one mounting plate.
 6. The apparatus of claim 5 wherein saidheader support base includes a longitudinal trackway and a plurality ofV-slide assemblies mounted on said trackway for selective relativemovement with respect thereto.
 7. The apparatus of claim 6 wherein saidV-slide assemblies include a baseplate slidable along said longitudinaltrackway, a standard extending outwardly from said baseplate, saidstandard having guide bearings thereon, a plate slidably mounted in saidguide bearings having a V-shaped notch in one end opposite said bottomplate for adjustable support engagement with said header, and aretention means for retaining said header against said V-shaped notch.8. The apparatus of claim 7 wherein said retention means is anadjuStable cable means entrained about said baseplate and fixed at itsends to said base
 9. The apparatus of claim 7 wherein said headersupport base further includes a first jack means for moving said plateof said V-slide assemblies in said guide bearings, and a second jackmeans for positioning said header longitudinally with respect to saidheader support base.